# INLET AND OUTLET SOURCE TESTING REPOR.T ON TI3E TUN

-

NEL KILN SCRUBBER HANLEY PLANT GLEN-GERY CORPORATZON SUMM[ERVILLE, PEN1o1SYL''VANIA Testing Dates: April 26 and 27, 2005

Prepared for: Glen-Gery Corporation Route 61, 423 S. Pottsville Pike P.O. Box 340 Shoemakersville, Pennsylvania 19555-0340

Prepared by: Air/Compliance Consultants, Inc. 1050 William Pitt Way Pittsburgh, Pennsylvania 15238 412-826-3636 PA Lab Registration #: 02-742 Project No. 05-083


# Air/tompliance Consultants,lnc.

# XNI,ET A.ND OUTLET SOURCE 'I'ESTING REPORT ON TH3E 

# TUNNEI., KILN S 

# CRUBBER

HANLF'Y PLA.NT GLEN-GER'Y CORPOR.A.TZON SUMMERVILLE, PENIti1SYL , VANIA Testing 13ates: April 26 and 27, 2005

Prepared for: Glen-Gery Corporation Route 61, 423 S. Pottsville Pike P.O. Box 340 Shoemakersville, Pennsylvania 19555-0340

Prepared by: Air/Compliance Consultants, Znc. 1050 William Pitt Way Pittsburgh, Pennsylvarria 15238 412-826-3636 PA Lab Registration #: 02-742 Project No. 05-083

P . 1

# SOURCE TEST REPORT S'I'ATEMEI`IT

This statement signed by the on-site supervisor of the test tearn and the source oujner/operator certifies that "to the best of th.exr knowledge" the source test repozt has been checked for completeness, and that the results presented are accurate, error-iree, Ipg ble, and representative of the actual eznissions measured during testing.

un-one oupervisor oz tne I esc a eaxn ,Air/Compliance Consurtants, Inc_



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# TABLE OF CONTEN'I'S Pa,c- , e

1. 

# ZNTRODUCTION .......................................------------...-----............-.----.............-.---..........----...........4

2. 

# TEST PERSONNEL ................................................................................................-•----........._.....4 3. SOURCE DESCRIPTION .................................................................................................•-----.._._4

4. 

# TESTING METHODOLOGY ...................................................................................................... .5 4.1. FLOW RATE, MOLECULAR WEIGHT AND iV10ZSTURE DETERMINATZONS ....... 5 4.2. PARTZCULATE MATTER, HYDROCHLORIC AND HYDROFLUORlC ACZD ......... 5 4.3. SULFUR DIOXIDE AND SULFURIC ACID MIST ........................................................6

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# 4_4. CEM DETERMTNATIONS ........................•-•----._............-.-----.........--------.........-.---............6 S

. 

# TEST RESULTS ....--. ........................................------....----------.............._.._.._........----.----._......._.......7 6

. 

# CONCLUSION ............................................................................-------............_......_......----.......-.---8

VYf`'TT't?Ti`C 

# 1. Process Flow Diagram 2_ Scrubber Znlet Sampling Location Schematic 3. Scrubber Outlet Sampling Location Schematic 4. CEMS Trailer Znstrument Configuration

' 7` A Y? 7'G' C 

# I. Particulate Matter, Hydrochloric Acid, and Hydrofluonc Acid T est Results, ScnZ bber Znlet Duct, April 26-27, 2005 2. Particulate Matter, Hydrochloric Acid, Hydrofluoric Acid and CEM Test Results, Scrubber Exhaust Stack, April 26-27 7 2005 3. Sulfwr Dioxide and Sulfuric Acid Mist Test Results, Scrubber Znlet Duct, April 26-27, 2005 4. Sulfur Dioxide and Sulfuric Acid Mist Test Results, Scrubber Exhaust Stack, April 26-27, 2005 5. Table Nomenclature 

# APPENDICES A. Testing Protocol and Relevant Correspondence B. Computerized Data Sheets and Field Data Sheets C. Equipment Calibrations and Certification Data D. Plant Process Data E. Laboratory Analytical Data F. Sam.ple Calculations

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# INLET AND OUTLE`I` SO - URCE TES'I'ING REPORT ON 7~HE TUNNEL KILN SCRUBBER

HAN L]E'Y PLANT GLEN-GERY CORPORA.TxON SUlYIMERVILLE, PENNSYL'VANIA 1. INTRODUCTION Air/Compliance Consultants, Ine. (ACCI) conducted a compliance testing program on the scrubber inlet duct and exhaust stack for Glen-Gery Corporation (Glen-Gery) at the Ha.nley Plant in Surnmerville, Pennsylvania_ T esting was performed for particulate matter (PM), hydrochloric acid (HCl), hydrofluonic acid (HF), sulfur dioxide (S02), and sulfuric acid mist (H2SO4) simultaneously at both locations_ Gaseous emission testing was conducted only at the outlet location for oxides of nitrogen (NO X ). Testing was completed at the request of the Pennsylvania Department of Environrnental Protection (PADEP). 

# 2. TEST PERSONNEL Testing was performed on April 26 and 27, 2005. The ACCI test team consisted of Mr. James Phillippi, Senior Project rv,tanager; Mr. Michael Matvey, Scientist; Mr. William Cowell, Senior Enigneer; Mr. Eric White, Senior Technician; and Mr. Patrick Walters, Technician. Mr. Hubert T. Flaherty of PADEP observed portions of the testing prograrn. Mr. Robert Stewart represented Glen-Gery. 

# 3. SOURCE DESCRXPTION Glen-Gery operates a tunnel 

# kaln to manufacture architectural brick. The Plan A.pproval Nuxnber for this source is 33-055A, and was issued on May X, 2002. The natural gas-fired kiln has a permitted capacity of 60 MM BEP/year, (16.62 tons/hour). The air pollution control device (APCD) for the kiln is a Catenary Grid Scrubber using magnesiurn hydroxide (M b [OH] z ) as the scrubbing liquor_ The scrubber was designed and installed by CECO Fzlters. The unit has a capacity of 45,600 actual cubic feet per minute (ACFM) at 450 degrees Fahrenheit (°F). A process flow diagram is included as Figure 1.

7:IAPR0!FCT1GIen-Gery Stick105-083 Summervil!elReporllCOMPtIAtJCE RcPORT-SCRUBBER.doc 

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# 4. TESTIitiTG METHODa1L(3GY

ACCI conducted the measurements in accordance with the United States Environmental Protectzon Agency (USEPA) Title 40 Code of Federal Regulatzons (CFR), Part 60 Appendix A, Testing Methods, and the PADEP Source Testing Manual_ Four test runs for each pollutant were conducted at four different scrubber operating parameters. Run 1 was conducted with 2 pumps operating and a scrubber solution pH of 5.45; Run 2 wzth 1 pump operating and a pH of 5.5; Run 3 with 2 pumps operating and a pH of 6.28; and Run 4 with 2 pumps operating and a pH of 4.53. 4.1. Flow Rate, N.[olecular Weight and Moisture Determinations ACCI conducted testing in accordance with USEPA Methods 1 through 4 at the scrubber inlet duct and exhaust stack. U'SEPA Method 1 was followed for selection of traverse points. Twenty-four sa.mpling points were utilized at the outlet location, 12 in each of 2 test ports. Twelve sainpling points were utilized at the inlet location, 6 in each of 2 test ports. Figures 2 and 3 include stack diagrams of the inlet to the sczubber and the scnzbber exhaust, respectively_ USEPA Method 2 was followed for the determination of gas velocity and volumetric flow rate. This procedure utilized an S-type Pitot tube and inclined manometer to determine stack-gas velocity head. USEPA ivletl
- lods 3 and 3A were utilized for the determination of CO?, 02, and stack-gas molecular weight_ Nztrogen (N 2 ) was determined by the difference. USEPA Method 4 was followed to determine the gas rnoisture content of the exhaust gas. A moistuxe determination was perfoxmed on each test run to allow determination of dry stack-gas nrzolecular weight and to calculate the dry standard cubic f.eet per minute (DSCFM) flow rate. The Method 4 train was incorporated with both the Method 5/26A sampling train and the Method 8 sampling trazn. 4.2. Particulate Matter, Hydrochlorzc and Hydrofluoric Acid USEPA Method 5 was followed to determine PM concentrations and mass emission rates. The Method 5 sample train included a glass n.ozzle, heated glass--lined probe, heated fllter, and chilled impinger trazn_ The front-half catch, which includes the acetone probe rinse, filter, and .front-half

L:1APR0.fECllG1Pn-Gery E3rlck\05-083 Summerviile\fteport\COMPLlANCE ftEPOR7•SCRUBBER.doc 

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# i Iter llolder acetone rinse, was gravimetrically analyzed to determine PIv1 emissions from the

source_ USEPA IVlethod 5 testing was coinbined with the USEPA Metllod 26A tests. ACCI determined the HCI and HF emission rates using USEPA Method 26A_ The back-half catch, which consisted of disti . 11cd water rinses of the back-half filter holder, all connecting glassware, impinger catch, and rinses, were a.nalyzed by ion chromatography (IC) to determine the Hl and HF concentrations. The last 0.1N 1_12SO4 impinger was analyzed separately to determine collection efficiency. Collection efficiency for both HCl and HF was 100%. Two USEPA audit samples were obtained and analyzed concurrently with the emission samples. The HCl audit 'samples were within specifzcations and were accepted_ HCl and HF samples were analyzed by Air Quality Services (AQS), PA L.aboratoz
- y R.egistration Number 02-41 l. Chain of Custody Forms accompanied samples during shipment. 4.3. Sulfur Dioxide and Sulfuric Aci.d 1VZxst USEPA. Method 8 was foll.owed to ineasure S0 2 and H2SO 4 emissions in the stack gases_ This method utilizes a glass nozzle and heated glass-lined probe which is cornnected directly to the impinger train. The first two ixnpingers contained an 80% isopr.opyl alcohol mixture. A.n unheated glass-fiber filter was inserted after the second impinger; the third and fourth impingers contained a 3% hydrogen peroxide mixture; and the fifth impinger contained silica gel. The second and fourth impingers were analyzed separately to determine collection efficiencies: Inlet and outlet testing were conducted simultaneously. Sampling trains were purged with clean ambient air at 0.75 cubic feet per rninute (cfm) for 15 minutes using separate pumps after the ftnal leak check was completed. Saxnples were analyzed using IC by AQS_ The collection efficiency (4 test runs) for the S02 sampling was 97.25%. The average collection efficiency (4 test runs) for the H 2 SO4 sampling was 100%. 4.4. CEM Determinations ACCI utilized a mobile continuous emission monitoring (CEM) vehicle for determining NO,, concentratrons in the scrubber exhaust stack. USEPA Method 

# 205, in conjunction with USEPA Protocol I gases, was used to create the correct range of calibration gases to verify the

Z:IAPR0JL"CT1GIen-Gery Brick105-083 SummervillelReporliCOMPLIANCE REPORT-SCRUBBER.doc 

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# instrumentation used in the test program. USEPA Method 3A was conducted during the Method

5/26A sampling runs in the exhaust stacic. 4.4.1. NOY Determinations USEPA Method 7E was used to continuously measure NTO, { concentrations in the exhaust stack. AThermo Environmental Model 10 chemiluminescent analyzer was used. An extractive gasconditioning system was used to convey the sarnple gas to the analyzer. Figure 4 contains a schematic of the CEM system. USEPA Protocol calibration gases were utilized to calibrate all Reference Method (RM) analyzers. Data acquisition was conducted with a multi-channel Yokogawa datalogger_ Data was saznpled continuously and scanned into memory in 2-second intervals. This data was used in the emission calculations. S. 

# TEST RESULTS All test results and pertinent testing parameters are included in the following tables:
Q 

# Table ]. contains the results of the scrubber inlet PM, HCI, and HF testizig * Table 2 contains the results of the scrubber exhaust PM, HCI, HF, and INTO X testi.ng
0 

# Table 3 contains the results of the scrubber inlet S02 and H2SO4 testing
0 

# Table 4 contains the results of the scrubber exbaust S02 and I3: 2 SO 4 testing

s 

# Table 5 contains the Nomenclature for all 4 Tables Appendix A contaxns a copy of the test protocol and relevant agency cornrespondence. To document the work perforxned, Appendix B includes aIl field data generated during the program including all manual method and computerized field data sheets, CEM l. -nu
- nute averages, and computenzed spreadsheets. Dry gas meter, pitot, thei
- mocouple, and nozzle calibration data sheets can be found in A.ppendix C. Calibration gas Certifzcates of .Anaiysis and CEM bias sheets are also contained in Appendix C. Relevant facility process/production data is contained in Appendix D; and PM, HCI, HF, S0 2 , and

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# HUO4 analytical data is contained in Appendix E. Sample calculations for one complete test nuz of

each pollutant are contained in Appendix F. 6. CONCLYJSZ0N A compliance test program has been conducted for trleil-Gery Corporation at their Hanley Plant located in Summerville, Pennsylvania. All of the testing has yielded data that is considered to be representative of the emission rates at fi.he prevailing operating conditzons.

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### Table 1. Pariicutate Matier, Hydrochloric Acid, and Hydrofluoric Acid Test Results, Scrubber Inlet, ApriI 26-27, 2005 Glen-Gery Corporation, Iianley Plant, Surnmerville, Pennsylvania

Test Data Run I Run 2 Run 3 Run 4 Average
Date April 26, 2005 ApriI 26, 2005 April 26, 2005 April 27, 2005 Start'firne 8:00 AM 11:08 AM 2:25 PM 7:50 AM End Time 9:02 AM 12:1 I PM 3:26 PM 8:51 AM Flow Rate (ACFM) 33,472 32,908 33,244 33,813 33,359 

### Flow Rate (SCFM) 20,444 20,037 20,112 20,454 20,262 Flow Rate (DSCFM) 18,191 18,148 18,498 18,612 18,362 Sample Volume (DSCF) 54.792 55.366 56.818 56.872 55.962 Carbon Dioxide (CO 2 ) (dry volume %) 6_00 6.00 6.50 7.00 6.38 Oxygen (O,) (dry volume %) 11.50 11-50 11.50 11.50 11.50 V4'ater Vapor (14 2 0) (volume %) 11.02 9.43 8.03 9.01 9.37 

### Stack Temperature (°F) 365.6 368_2 373.5 370.7 369.5 Percent of Isokinetic Sampling (%) 98.45 99.72 100.40 99.88 99.6 Results Particulate Matter 

### Mass Collected (m
~ 

### ) 84_40 137.05 117.10 102_95 110.38 Emission Concentration (gr/DSCF) 0.0238 0.0382 0.0318 0.0279 0.03 Emission Rate (Ib/hr) 3.7059 5.9412 5.0421 4.4559 4.79 Emission Factor (lb/ton product) 0.284 0.455 0.386 0.341 0_367 Hydrochloric Acid (HCI) Emission ivfass (total) (mg) 9.70 11 _20 20.70 13.80 13.85 Coliection Efficiency (%) 100.00% 100.00% 100.00% 200-00% 100.00% l:mission Concentration (ppm d „) 4.12 4.71 8_49 5.65 5.74 Emission Rate (lb/hr) 0_43 0.49 0.89 0-60 0.60 Emission Factor (lb/ton product) 0_0326 0.037 0.068 0.046 0.046 I-Iydrotluoric Acici (H;') Emission Mass (total) (mo) 348_84 276-2 328.1 3I8.60 317.94 Collection Efficiency (%) 99.87% 300.00% ] 00.00% 100_00% 99.97% Emission Concentration (ppma„) 270.32 211.91 245_ 18 237.85 241.29 L'mission Rate (Ib/hr) 15.32 11.98 ) 4.13 13.79 13.80 Emission Factor (lb/ton product) 1.174 0.918 1.083 1.057 1.058 CFM resulte have been bias calibration corrected. Values that are less than 0 are reported as 0 in the Table and are included in the Avera.ge as 0.

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# P. 15Table 2. Particulate Matter, Hydrochloric Acid, and Hydrofluoric Acid Test Results, Scrubber Exhaust, April 26-27, 2005 Gleri-Gery Corporation, lianley Plant, Summerville, Pennsylvania

Test Data Run I Run 2 Run 3 Run 4 Average
Uate Apri126, 2005 Apri126, 2005 April 26, 2005 April 27, 2005 Stai
- t Time 8:00 AM 11:08 AM 2:25 PM 7:50 A1vt Fnd Time 9:03 AM 12:11 PM 3:26 PM 8:51 AIvI Flow Rate (ACFM) 29,001 29,918 30,068 29,756 29,686 Flow Rate (SCFM) 25,209 26,050 25,974 25,811 25,761 Flow Rate (llSCFM} 22,181 23,061 22,783 22,683 22,677 Sample Volume (DSCF) 67.297 63.502 55.850 5S.942 60.648 Carbon Dioaide (CO

Z ) (dry volutne %) 2.12 1.58 0.87 1.02 1.40 Oxygen (0 2 ) (dry volume %) 17.07 18.14 19.01 19.00 18_31 Water Vapor(11 2 0) (volume%) 12.0I 11.47 12.29 12.12 11_97 Stack Temperature (°P) 119.8 118.5 120_4 120.0 1 19_7 Percent of isokineiie Sampling (°i°) 97_00 95.22 95.94 96.52 96.2
Resnits 1'articulate Matter Mass Collected (mg) 168.55 166_60 130.15 127.70 148.25 Emission Concentration (gr/DSCF) 0.0386 0.0405 0.0360 0.0352 0.0376 Einission Rate (lb/hr) 7.3473 8.0018 7_0219 6.8483 7.3048 Emission Factor (lb/ton product) 0.5630 0.6132 0.5381 0.5248 0.5598 Nitrogen Oxides (NOx) as NO 2 Emission Concentration (ppin d „) 20.4 16.6 10.6 9-3 14.2 Emission Rate (lb/hr) 3?4 2.74 1.74 1_51 2.31 Emission Factor (Ib/ton product) 0.249 0.210 0.133 0.116 0.1769 iiydrochloric Acid (110) Emission Mass (total) (ug) <_06 <.06 <,06 <.06 <_06 Collection Ffficiency (%) NA NA NA NA NA F:mission Concentration (ppm & ) NA NA NA NA NA Emission Rate (lb/hr) NA NA NA NA NA Lmission Factor (1b/ton product) NA NA NA NA NA Hydrol7uoric Acid 

### (HF) Emission Mass (total) (mg) 0.88 5.1 0_8 0.83 1.90 Coltection Efficiency (%) 100.0% 100.0 0 /0 100.0% 100.0% 100.00% D.:mission Concentration (ppm d „) 0.56 3.41 0_61 0.04 1.15 Emission R-ate (lb/hr) 0.04 0.24 0.04 0.04 0_09 Fmission Factor (lb/ton product) 0.003 0.019 0.003 0.003 0.007 CEM results have been bias calibration corrected. Values that are less than 0 are reported as 0 in the Table and are included in the Average as 0.

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# P. 16Tsb1e 3. Sulfur Dioxide and Sulfurie Acid A4ist Test Results, Scrubber inlet Duct, Apci126-27, 2005 Glen-Gery Corporation, l-Iantey Plant Surm;terville, Pennsylvania.

Test Data Run I Run 2 Run 3 Run 4 Avrrage
Dste April 26, 2005 April 26, 2005 April 26, 2005 April 27, 2005 St:ut 1'ime 9:45 AM 12:33 PM 4:28 P-N4 9:08 AM F:nd Time 10:48 AM 1:361'M 5:30 PM 10_ 10 AM Tlow Rule (ACPM) 33,113 32,677 34,671 33,608 33,517 i=1ow , Ratr (SCFM) 20,164 19,844 20,956 20,347 20,328 rlo.v Rate (llSCFM) 17,151 18,600 19,198 18,422 18,343 Sanlpie Volume (DSCF) 46.043 46.329 49-753 47.695 47.455 Carbon Dieaide (CO,) (dry volume %) 6.0 6.0 6.0 6-5 6-1 Oxygen (O,) (dry vrolume %) 11.0 11.5 11.5 11.0 11.3 Vdater Vapor (1i"0) (volurne %) 14.9 6.3 8.4 9.5 9.8 Stack Temperature (°F) 368-1 370-3 374.3 370.6 370.8 Pcreent of Isokinetie Sampling (%) ] 04-4 96.9 100.8 100.7 100.7 Results Average Averoge Runs 1-4 Runs 2-4 Sulfur Dioxide (SO i ) "• n•tatis Coilected (mg) 130-5 1184.4 1233.2 1159.80 926.98 1192.47 Fmissinn Concentration (1bnDSCF) 6.25Y-06 5.64F-OS 5.46E-05 5.361E-05 4.2721:-05 5.487E-OS Emission Concentration (ppm d „) 37.6 339.3 329.0 322.75 257.16 330.34 Emission Concentration (ppn d „ a ~ 7% O i ) 52.8 501.8 486.5 347.01 347.01 445.07 Fmission Rate (Ib/hr) 6.4 62.9 62.9 59.26 47.88 61.70 Colicction Efficiency (%) 92.0 99.0 99.0 99.0 97.3 99.00 Ernission Factor (lb/ton product) 0.4927 4.8200 4.8232 3-3786 3.3786 4.34 Sulfuric Acid ( 11 2S 0 ,) A4a_<s Collcctcd (rng) 59.0 79.3 101.7 106.70 86.68 95.90 Fntission Concentratiort (Ib/DSCF) 2.83E-06 3.77F_-06 4.5IE-06 4.932E•06 4.009T-06 4.4041
- •06 Fmiscion Concent:ation (ppm a .,) 11.1 14.8 17.7 19-39 15.76 17-31 F_missionConcentration (ppin, ) .@7%O z ) 15-6 21.9 26-2 27.23 22.74 25.12 limi;sion Rate (lb/hr) 2.9 4-2 5.2 4.10 4,10 4.50 Coltrr,tion Htiiciency (%) 100.0 100-0 100.0 100.0 l00.00 100.00 Emission Factor (Ibltort product) 0.2228 0.3227 0.3978 0.3144 0.314 0.345

JU ; re>ult tiOm run 1 iS cun5idveJ an Oullier, aver.rge resullti are Rivrn b01h including:fnd "cluding Kun I

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### 'Iable 4. SuiFur Dioxide and Sulfuric Acid Mist Test Results, Scrubber Exhaust Stack, April 26-27, 2005

Glen-Gery Corporation, i3anley 1'lant, Summerville, Pennsyivania

_- -- - - -- -- --- 

### 'fest Daia _ - _ _ . Run -t- - --- -- .__ .. ._-. - Run Z -- ------..-_ Run 3 - -- -- Run 4- ... _ .. - Avetage
Date April 26, 2005 Apri126, 2005 April 26, 2005 Apri127, 2005 Start Time 9:45 AM 12:33 PM 4:28 PM 9:08 AM End Time 10:48 AM 1:36 PM 5:30 Plvl 10: l0 AM 1 10w Ka;e (ACFM) 29,046 30,070 30,588 29,876 29,895 Flow Rate (SCFM) 25,260 26,085 26,446 25,932 25,931 Flow Rate (DSCFM) 22,579 23,027 23,352 

### 22,924 22,970 Sample Volume (DSCF) 40.178 37.236 38.339 36.844 38.149 Carbon Dioxide (CO2) (dry volume %) 2-0 2.0 2.0 2.0 2.0 Oxyaen (O : ) (dry volume %) 17.5 17.0 17.0 17-0 17.1 

### Watcr Vapor (H 2 0) (volume %) 10.6 11.7 11.7 11.6 11.4 Stack Temperature (°F) 119.3 118.8 119.9 119.7 119.5 Fercent of lsokinetic Samplin ~ 

### (%} 96.1 96.8 98.3 96-2 96.9 Resufts 

### Sulfur Dioxide (SO,) Mass Coileeted Ernission Concentration Emission Concentration 1-3 mission Concentration Emission Rate Emission Factor Srrlfuric Acid (11,S0 1 ) tid'ass Coilccted 

### 1=,niission ConcentratiOn Emission Concentration Emission Concentration Emissiorn Rate Emission Factor (lnn) 630.1 668.4 355.8 624.9 559.80 

### (lb/DSCF) 3.46E-05 3.96E-05 2.05E-05 3.739E-05 3.300E-05 (ppm & ) 208-1 238.2 123.2 225.11 198-67 (ppm, t „ @ 7% O,) 851-0 849.1 439.0 713 -03 713.03 (1b/hr) 46.8 54.7 28.7 5) -43 45.40 (lb/ton product) 3.589 4.190 2.197 3.941 3.479 (mg) 47.1 57.7 50.5 40.2 48.88 

### (lb/DSCF) 2.58L-06 3-42E-06 2.90E-06 2.4051: --06 2.827E-06 (ppm d,,) 10.2 13.4 11.4 9.46 11.12 (ppm, l „ @ 7% O,) 41-5 47.9 40.7 43.37 43.37 (lb/hr) 3-5 4.7 4.1 3.31 3.90 (Ib/ton product) 0.268 0.362 0.312 0.254 0.299

Z'!.%+RF:OJECT :Grr n-Gery 8rickl05-063 Summervillelf ie!d Testiny-Apri12005\G!en-Gery Summervi0e Teb!es, Table4 6/1 OR005 

# P. 18

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# P. 19

# XNLET A.ND OUTLET SOURCE TESTING REPORT ON THE T

~



# JNNEL KILN SCRUBBER HANLEY PLANT GLEN-GERY CORPORATION SUMMERVILLE, PENNSY
- LVANYA Testing Dates: April 26 and 27, 2005

Prepared for: Gien-C'xery Corporation Route 6I, 423 S. Pottsville i'ike

P.Q. Box 340 

# Shoemakersville, Pen,nsylvania 1 9555-0340

Prepared by: Air/Cornpliance Consultants, Xnc. 1050 WilJ.iam Pitt Way Pittsburgh, Pennsylvania 15238

412-826-3636 

# PA I,ab Registration #: 02-742 Pzoject No. 05-083

P. 21

# SOURCE TES`I` REPORT STATEMEN'f

T'n?s statement signed by the on--site supervisoz - of the test team and tl
- ie source owner/operator certifes that. "to-the best of their knowledge"-tbe soturce test teport has been checked for completeness, an.d that the results presented are accurate, ez
- ror-free, legible, and representative of the actual ez
- nissions measured during testing.

James F. Phillippi Senior Project Manager On-Site Supervisor of the Test Teanz Air/Compliance Consultants, Inc.

TZobert Stewart f;nvironxnental Ma.nager Source Owner/Operator Clen-Cery Corporation

P. 2 2

# R E C E I V E D APR 2. 5 2095. - : ,

'~ ~ ~ 1~ ~ .. _ ~ ~ • .~ ~ ~~;

~ ~~ E ""• . t ~~ ~ ~ ,~ ~.

. ~
. 

# Pennsy'ivania Department of Fnvic
- onmental Protecfion

- - .



# Racliel Carson State Offce Buildin Dto,
Bureau of Alr Quality Post-O-ffice Box 8468 Haz
- risburb, Pennsyivania 17105 -- 8468

Aprill 7, 2005

Mr. Robert Stewart Glen-Gery Corporation 423 S. PottsviIle 

# P.O. Box 340 Shoemakersville, PA 19555 1 - 1 r"M

~~ ~ 

### `ti 

## _ _ . t: t ~ } ~ 

## j l,j 1. . _~ (•~i' .



# Dear Mr. Stewart: Qn March 23, 2005, the Department x'eceived a procedural submission for hydrogent chlor7;de and hydrogen fluorade (EPA method 26A), sulfur dioxide and sulfuric acid misfi (EPA xnethod 8), NitTogen Ox•ide (EPA method 7E), and Particulate (EPA rnethod 5) on the scrubber inlet and outlet at Glen-Gery Corporation in Summerville Borough, Jefferson County. Testing will be conducted to demonstrate compliance with the conditions of Plan Approval No. TV-33-00055. `i'he test protocol is unacceptable to the Department untess the following conditions are xnet: oHCl/HE, and SO, t removal eff cienczes as well as outlet mass eznission rates sllould be reported in lbs./lu'.

~ 

# Testing shall be perforined while the kiln is operating at the maximurn production rate and while using raw n
- iatezials that contain the highest concentTations of fluorine, chlorine, and sulfur fihat wi11 be used in the kiln.

~ 

# Zn accordance with the Souxce Testing Manual section 2.$ (rev. 33) sampling trains shall achieve a collection efficiency of >_95°/fl. Collection efhciency for EPA Method 26A (HCL) can be determine by analyzing the two impingers containing acidic solutions separately. This is done to ensure that there is no break through from the second impinger.

~ 

# The final test report must include at least one complete ernission calculation for pollutant tested. This calculation actually irnplements stack test data in equations (and not just calcuiation fonnulas) to verify test result accuracy

~ 

# All required audit samples must be ordered at least tliirty (30) days prior to the test date.. Please submit the written r
- equest to:

An tqua lOpportunity Employct 

# Gvww.dep.state.pa_us i'rinied on Recycted Paper 

# P. 2 3

# - 2 - Apri17, 2-005

Mr. Bryon Richwine fiureau of Air Quarity

~ 

# ivision of Source Testing and Monitoi
- ing Quality Assurance Unit 400 IV.larket St_, RCSUB (12 Eh floor) Harrisburg, PA 17105-8468 Biyon Richwine of our Quality Assurance Unit must be notified of the results by teleplaone (717- 787-9483) and the iresults included in the test report_ 0 Cotttact Dave Bubbenrnoyer (814-723-3273) regarding process operation during test. Please inform Dave Bubberarnoye7r of our Northwest Regional Office and me at least two weeks prior - to test of the ach,ial date and time of test_ Fiiial acceptance ofthe test repUrt wiil be contingent upon fulfilling the aforementioned conditions and all applicable i
- equiz
- ements specified in Title 25,Chapter 139 of' the PA Code; Pla.n Approval No TV--33-00055; and the Department's Source Testing_Iylanual (Revision 3.3, November 2000). If there are any questions regarding this matter, please contact :ne at your convenience_ Sincerely,
c .~ 

# `--_ ~ 

# Rajdeep Singh Bhangu Source Testing Section Division of'Source Testing and 1Vlonitoring
cc. r _ Jaanes Phillippi Air/Corxipliance Consultants, Tnc. 1050 William Pitt Way Pittsburgh, PA 15238 bcc: Red Uata File, Glen-Gery Corporation, Surnmervxlle Borough, Jeffei
- son County Dave Bubbenmoyer
- , Northwest Regional Reading File, Source Testing 

# TRB:R.SB:rsb

P 24

# y~ 

# i0 , ~~~ 

# /Comp 

# liance

consuffunts, Inc. Ivlarch 1 b, 2005 Mr. IZajdeep Bhangu PADEP, Bureau of Air Qirality Souz
- ce Testing Section Rachel Carson Siate Office Building PC_) Box 8468 Harrisbu.rg, Petunsylvania 17105-8468 RL: Submit

- tal of Test Protocol Dear Mr. Bhangu: P1

- oject Nuwnber 0.5-483

AirfCompliance Consultants, rnc- (ACC1) will be contr
- acted by Glen-Gery Corporation to conduct testing ozz the inlet and outlet of the wet scrubber at their I4anley Plant in Sumn
- rerville, Pennsylvania_ The iest will follow the previous submitted.lVlarch 8, 2003 Protocol (attached) tivith the following revised contact inforrn.ation: Testin 

# Jarnes PhillippiAirlCornpliance Consultants, Inc1050 VVilliam Pitt Way Pittsburgh, PA 15238 412-826-3636 — Plzone 412-826-364(} — Fax 

# ,jphiili@air-comp_corn 

# L aboratoiry Nancy Kotsko Air Quality Servzces 4527 Clairton Boulevard Pittsburgh, PA. 15236 412-881-5630 — Phone 412-881-7925 — Fax 

# PA Lab No.: 02-7I 1 

# 'llent R.obert Stewart (31en-Gery Corporation 423 S. Potfsville, Box 340 Sboemakersville, PA 19.555 

# 610-562-2084 — Fax 610-562-3076 — P}ione 

# bstewart@glcngerybrick.comThe conditions presented in your 1Vlarch 26, 2003 approval letter (atfaclied) will also be followedUzlder sepaz•ate lettei
- , audit saniples wiil be requested f

~ 

# om Iv.lr, Bryon Richwine.. Please call us at (412) 826-3636 if you have any questions. Sincerely, 

# AIR/C:OMPL. ~.~fJ

- 

# VCE CO1ITSZI'LTANT5`, INC.:

, 

### 7~P~ 

# ames E_ Phillipp

i Seruor Project Manager .3EP/RNT-:s1.I Enclosures cc: Ivlr. Robert Stewart, Glen-very Corporation

ZNFt°r2oJC;C11Glen•Geiy Br;cklSummervilielLO7 L(r Pratocai RajdecP BhanQu dDc 

# ~ ~ Robert N. Frey Vice President

l OS0 Wifliam Pitt tiYay 

## Pitfsburgh, P'A 15238 

# 412-826-3636 412-876-3640 (ax 

# P_ 25

# TEST 1VEt 'I'HOD CERTIFICA'I`I4N

GIen-Gery Cniporation and Aiz/Coznpliance Consultants, Znc. have conducted a review of the state and iederal regulations which apply to each source at Glen-Gery Corporation, in order to develop the test methods descr
- ibed in fllis protocol_ We certify, to the best of our k.aozvledge, that the test methods that have been incorpor
- ated into the atiached protocol meet the testing rertuiremenEs of' the applicable regulations. Inlet and OutIet Wet Scrubber Test Protocol Suxnmervilie Plant Glen-Gery Corporation .A.CCI Project No. 05-083



# ,~.~ ~ ~ . •~ Jarrz.es E. Phffl}ippi Senior Rzojeot Manager AixlCorrrplianc6 Consultants, Tnc.

tewast 

# Envirot.menfal Manager fxlerx- ~ 

# 'rery Corporadon

Z_1APR0jr--CT1G1cn-Gcry Brick\05-0$3 SummcrviilelSignoffPsgc Aor Proiocol.doc 

# P. 26~ ~ 1■■ 

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### 3131 Uisney S

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### L- + ~ce 1.. t~

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### 'ita.c" iun.aLi. r Ohi'ti 4$2,DR (513) 35I-6200 (513) 35I-d•D7X


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# ?
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# t `'YRSSION ITSTPRaT4COL DBT" , ~~ 

## '-A-TION flF PARTICULATE AATI T ER, 

# SUf YURDIOXIDE,, MDR0 C-FN CEU- ORML AND _ MRO G-tK Z`L'U0EM E , livZM SIONS AT THE 

# IN
- 11 , X AND OTJTlxtT OV TFM WET SCRUB13E.R, fx7UN- ''I
~ 

# Y CORJ'OP`

4.AUON YIAN3E,EY PLANT SMMMIMLL 

## ,E, PA.

OXcxt Gery2'cojectC`

,00rclsa,af.a5c: Enviroumental. Msn ager 

## M ailing Addxess' P_O_ Bos 3

~ 

## i0 0 

## haf:ma1cus-d11e, PA 195
~ 

## 5 

## Z`elepbone (6I0) 562-3(}76 

## Plant Address: Route 2$ Summerville, PA, 1586"066 

## SubmzftE-,d byz KB)D r1` o ' cBmC, 1ac.



## Cz-a.ig R, JJones 

# Vice President

JoT

~ 

### T - ur p-1457 

## Karcb. S, 2003



# Q. 27

## Fe(?O- T-384 P 004I037 F -2 'S



# To
- if
- he best o ~ 

# Tt2.3► 

# knowledga s ti

~ 

# e sfaGe dnd federczl r

~ 

# ef;

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# t7

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# itzorts, opet'aiit2g perrnit6 1 or plan dpprovals applicable tcs eceA sozr.rce oT conti
- oi dEvice ki be tested hccvt been reviewed and that aZl tesHng reguiremenes therezn 1`caue been incorpo

# rated inio the iest plan_

cxl ai; R, Jones RobextSt

~ 

## .-cx-[: 

## Vice pze6dmt En.v'zronmental Max3agex 

## 1£ED `FECILNSC y Iitl'{I Gle.r

~ 

## -Gery C;ozpox aticcn



# P. 28

### li

~ 

### 41'- ~0-~~ 

### FRo}f- 

## T-3B4 p 905/03i F-25E

_ ... . . _ . . 

## 1.0
- 

## 17MOD27C ~'.~~I1 

## ...... 

## The objeedve af the tasf program is bo detexzoune coampliaz

~ 

## eo 'Wifh X'la.tl

~ 

## pproval NurYtber 33 t?55 ~ 

## Bznzssion tests are tobe cozicl
- xcted fQr paz
- Eculate xnaeex

- (PM), zt.ztrogen. o:ddes (NO x ) stil- ,q Lr cto4de (SQ, 2 ), su].Fuuic aci.d mist (H,90,), hyc.

~ 

## 'rogen chIoride (73CI) and ;ydrogca fluoriae CHF1- Emzssion samples ar'e to be collected usx7rg USEPA IvZethods 7, 2, 3, A 6, 'fE, 8 ancd 26A The fi.r ~ 

## program wffl cake place d uring 

## the weel;. of Apffl 14 ; 2003_ IMI} 'pECRNI:C Nvzll condml; the Aeld tests 

## and analgLe the particular,e sahiples. DataClxexn Laboremries wiu perforIn tb-- anelysis for S0 2, ILSO„ 73C`l and HFTt , S`nNG Ct?MLPANYCON£ACT LA.730RAT0RY CON'I'ACT DMORMATION IlT , OR€YfA.TwN 

## KED TBCIRN'IC IIaLaChem Laborataries 3131 Dismey Stzeet 4388 Ex]endele--7Vlilfoxc.d Road. Cinci=ati, OOH 45209 Cinci.mata, OH 45262 (513) 351: 62a0 ( 5I3) 73M336 

## Craig Jorces Ed Slic

~ 

## :. Yice Presictem Leb Kanager Peansylvania Repisfz'atzorz f68

- 

## 1320
2.0 

## PXtO CE

, SS jgff ORMA 7

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## us so'nxce is 33-4S5.A, i-gsued ort aVlay 1, 2002. TIae gas-nred Isilu ha9 a capacitf of 60 NfN1 BEP)year (26_62 tonslb.our), T4e aii pollation coxztroI. dev:ice (APCD) f
- ox Lbe IsiIa is a Cateuary Grid Scnibber usi.azg magneszum hydz
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## The scz
- abber vras desigrzed and installed. by CECO FiltGrs- The vnit Las a capacit
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~ 

## iguxe 2_1_ The ~ 

## fblIowing process paxameters will ba recarded durTrrtg fhe tesfs by Olen-Cer;}r aurl,/o:r MO pex'soxz

- o.el tb vezdCy tbAthe tesf.s axe cortdttcted at fhe rated capacity - azzd fbe maximixrn zzorMal opex:abing coxidit7ons: I_ lOn thxoughput 

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# P. 35

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March 22, 2005 Mr. Bz
- yon Richwine Bureau of Air Quality Division of Source Testing and Moiiitoring Quality Assuraiace Unit 400 Maz'ket St., RCSC3B (12` h floor) Harzisburg, Pennsylvania 17105-8468 R.e: Request for Atidit Sanzpies Dcai - lv1r.

~ 

# ichwine: Pr-oject No. 0.5-083

We aze planning fo conduct testing for the Glen.-Gery Coi
- poratioii.. Testing will be conducted at. tl
- Le Sun
- unerville, Pennsyivanaa an A.pril 25, 2005_ A11 fiesting will be connpleted in accord.ance witli Uriited States Enviromn.ental Protection Agency (USEPA) Methods 8 and 26A. We are hereby requesting one USEPA Method 8 and one 1vlethod 26A Audit Samples for our tests. Attached please f

~ 

# nd an Audit Sa.nlple R.equest form.. Sincez
- ely, Ai:r/Compliance Cojrstcl,ffflits, Itzc_
, , t ,

~ 'x ~ ' 

# / obert r

.~ 

# anles E. Phillippi N. Frey Senzor Pro,ject Manager Vice President

cc: Mz. I3ob Stewart, Glen-Gery Corporation Atach.ment

105U Wiiliom Pin Wny Pillsburgh, PA 15238 412-826-3636 412-826-3640 fax 21MPRO3FCT1G1en-Gery ©rickl05-033 5urnmerviliek.r+u6il 5arsple Request doc 

# P. 36

## Audit Request Number: (To be compieted by EPA) 

# AudEt Sarnple Requesf FGrtn 1. Name of Source C?wnerlC)perator GTer;-Gery 

# Corporation,
- Bob
- Sfewart - Address: Street Route 61, 423 S_ Pottsville Pike, P.O. Box 340 

# City Shoemakersville State Pennsylvania Zip T eEephone 61 J-562-3076 e-MaiE unknown 2.. List of requested audit samples: 19555

Number of Sarn les Sam le Method Target Concentration Date Needed Test Date .1 8 lovv-rr2id A ril 22, 2005 April25, 2005 7 26A low-mid April 22, 2005 A ri125, 2005 3. Shipping address if different from above;



# Company Ait'fCornpliance Consultants, Inc. Street 1050 tNilliarrr Pitt Way City Pittsburqh 

# State PA 

# Zip 15238 Attention Jtm Phillippi Telephone No. 412-826-3636 4. Test Site: Piani Narne 

# Glen-Gery Corporation

Address State Route 28

Summerville 

# Pennsylvania 15964 5. Special Shipping Instructions:

4p;c;ecVdu1"erco farrelf/Audit Sarrzpla Request farm-pa 3117/2005 

# P_ 37

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wwvr.erg.com 

# April_ 18, 2005 Bz
- yon Richwine PA Dept. of Environruental Protection, Bureau of Air Quality 1"2 th Fioor RCS0B, 400 Market Street Harrisburg, ]PA 17101 (717) 787-9483 

# Dear Mr. Richwine: Fastern Research Group (ERG) has been directed by the U.S. EPA to provide you with two ampules of audit material for a Method 08 SO Z I iV,iethod 08 SulfrYric acfd mist audit: M08-2264-01. These samples are for an audit at Glen

- 

# Gery Coz
- p . in Shoemakervidle, PA and are being sent directly to Jarnes PhYllippi of AirlCompliance Consultants, Znc in Pittsburgh, PA, pez your autornated datalbase request. 

# 1Vlethod 08 SO 2 z - equest 1VZ08-2264-01: -• one each S0 2 audit sample; Sample No. G , 0280 Metlaod 08 Sulfuric acid xnist request iYZ08-2264-01: - one each Sulfuric acid mist audit sample; Sample No. H- 0316 Please note that each sample is shipped with an instTuction sheet and a data form for listing the analytical audit infonnation. All results are to be reported by the requestor to the internet autozn.atecl computerized database. You are urged to instruct the laboratory to analyze the audit sample along with the designated field samples. The audit sample should be analyzed as a routine field sampie according to the specifications of the Test Method and using the supplied instructions. The audit results are to be reported to you, the requestor in the urnits speciffied in the instructions. You then will use the automated database to enter the results into the SSA.P database, VVe would -like to thank you for your participation in the Stationazy Source Audit Program. Zf you have any questions concerning the audit, please contact either Ms. Judi McCartney (91 9) 468-7920 or myself at (919) 468-7928. IVIy fax mumber is (919) 468-7803. Sincerely, :}

~ 

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# .. , Rick Lafleur cc: Shipped with audit sarnple
1600 Perimeter Park, Morrisville, NC 27560-8421, Telephone: (919) 468-7800, (Office) Fax: (919) 468-7801, (Lab) Fax: (919) 468-7803

- Arlington, VA - Atlanta, GA - Austin. TX • Boston, MA - Chantilly, VA - Chicaho, IL • Faii
- field, CT I-;arrisburg, PA • Kansas City, KS - Lexington, MA - Nashua, NFi - Reseai
- ch lriangle 

## r, - irk., Morrisvilie, NC • Sacrarr;ento. CA 

## ~ 

# P. 38im
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### www- erg.com 

# April 18, 2005 Requestor: Bryon Richwine PA Dept. of Environmental Protection,l3ureau of Air Quality 12 th Floor RCSOB, 400 iVlarket Street Haz
- risburg, PA 17101 ( 717) 787-9483 

# Dear :Mr. Richwiaae: Eastern Research Group (ERG) has been directed by the U.S. EPA to provide you with the following audit lnaterial for.a Method 26A HCI audit; Numbers M26A-2264-02 and -2264-03. These audit'samples are for ar-, upcnining audit at Gleii-Gery Corp. ira Shoexnakerville, PA and are being sent di.rectly to -Tames Philiippi of Air/Compliance Consultants, Znc in Pittsburgh, PA per your automated database request. Please note: requests for Method 26A are now filled separately frofn requests for Method 26 and that there are NEW lnstructions associated with these saznples, ef£ective October 2003.

1vit-tlinri 7 CN A 

# recluest M26A-2264-02: - one Method 26A. HCI sarnple; Sample No. M- 1944 request 1\426A.-2264-03: - one Method 26A 1-iCI sample; Sample No. iYl - 1761 Please note that each sample is individually labeled and shipped with an instruction sheet with the foxznat for reportiifg the laboratory audit results. All results are to be reported to the inteniet automated computerized database. You are urged to instruct the laboratory to analyze the audit samples along with the designated field samples. "fhe audit sample should be analyzed as a routine freld sample according to the specifications of the Test Method and using the supplied instructions. The audit results are to be reported to you, the requ.estor, by the analyst, using the Repoi
- ting , Form, in the units specified in the instructions. 'L'ou then will use the autornated database to enter the results into the SSAP database. We would like to thank you for your participation in the Stationary Source Audit Program. If you have any questions regarding the samples, please contact either Judi McCartney at (919) 468-7920 or myself at (919) 468-7928. My fax number is (919) 468-7803. 

# Sineerely, r.
s ti 5 t [ ~ 

# . _ ~ 

# .. ~ 

# . _ ,....,, ~ 

# ....,._.. Rick Lafleur 

# cc: sent with audi.t sarnple 1600 Perimeter Park, Morrisville, NC 27560-8421, Telephone: (919) 168-7800. (Office) Fax: (919) 168-7801, (Lab) Fax: (919) 468-7803

^ Arlington, VA - Atlanta, GA - Austin, TX - Boston, MA • Chantilly, VA • Chicago, IL • Fairfield, CT - f-larrisburg, PA - Kansas City, KS • I.-exington, MA - Nashua. NH • Reseai
- ch Triangle Park, P'lorrisville, NC - Sacramento, CA r_. _t -_.._.... C
~ „.. ~ ....,... . U::.,,,,,-I ,.n Rnr_lo.i A,n..r 

# P. 39